Side-by-side dual pump and motor with control device

ABSTRACT

The present pump devices provide a dual pump using two (or more) electric motors (e.g. brushless DC motors) driving the pumps independently, including integration of hydraulic and electrical components and connectors. The illustrated arrangements include an in-line single shaft version, a parallel side-by-side separate shaft version, and an inside-outside version. Each configuration includes a housing supporting formation of: shared structural support for the pumps and motors (e.g., bearings, stator, relationship of components), fluid pump and hydraulic system (e.g., fluid passageways, ports connectors) and motor electrical control (e.g., control circuitry and sensory components).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/664,758, filed on Oct. 31, 2012, entitled DUAL PUMP AND MOTOR WITHCONTROL DEVICE, which claims the benefit of U.S. Provisional ApplicationSer. No. 61/642,712, filed on May 4, 2012, entitled TANDEM MOTOR ANDPUMP AND CONTROL DEVICE; U.S. Provisional Application Ser. No.61/662,548, filed on Jun. 21, 2012, entitled SHARED-SHAFT TANDEM MOTOR,PUMP AND CONTROL DEVICE; U.S. Provisional Application Ser. No.61/665,072, filed on Jun. 27, 2012, entitled SIDE-BY-SIDE TANDEM MOTOR,PUMP AND CONTROL DEVICE; and U.S. Provisional Application Ser. No.61/665,082, filed on Jun. 27, 2012, entitled INSIDE-OUTSIDE TANDEMMOTOR, PUMP AND CONTROL DEVICE. The aforementioned related applicationsare hereby incorporated by reference in their entirety. This applicationis co-pending with another divisional application filed on even dateherewith, U.S. patent application Ser. No. 14/718,692, entitled IN-LINEDUAL PUMP AND MOTOR WITH CONTROL DEVICE.

BACKGROUND OF THE INVENTION

The present invention relates to integrated dual motor and pump devices,where the device includes at least two pumps operated independently byseparate brushless DC motors and incorporated into a unitary housingwith a common controller board providing for optimized function,features, and characteristics for defined and minimized package spaceand minimized assembly cost and time and components, while beingoptimized for operation.

Dual piggyback-type pump devices are known. However, improvements aredesired in optimizing their function, features, and characteristics forsmall package space and minimized assembly. For example, there is adesire for reduced cost of manufacturing, reduced number of individualparts, less assembly time, and less material handling and inventoryingof parts and components. Further, an efficient design is desired thatuses less total material, that is more integrated, and that take greateradvantage of common use of components (e.g., electrical connectors).Also, minimization of package space, while maintaining independentcontrol and operation of the motors and pump sets, including acapability of variable output, is desired to provide significantcompetitive advantages. It is preferable that all of this be done whilemaintaining design flexibility and a robustness of the design.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a combination dual pump and dualmotor device comprises a housing overmold; first and second shafts thatare parallel and each having an overmold-supported portion supported bythe housing overmold; a first volute attached to a first outer end ofthe first shaft and with the housing overmold defining a first pumpcavity at the first outer end and a first inlet to the first pump cavityand a first outlet and a first passageway extending from the first pumpcavity to the first outlet; and a first rotor assembly operably engagingthe first shaft and having a first pump impeller in the first pumpcavity. The device further comprises a second volute attached to asecond outer end of the second shaft and with the housing overmolddefining a second pump cavity at the second outer end and a second inletto the second pump cavity and a second outlet and a second fluidpassageway extending from the second pump cavity to the second outlet;and a second rotor assembly operably engaging the second shaft andhaving a second pump impeller in the second pump cavity. A first statoradjacent the first rotor assembly and a second stator adjacent thesecond rotor assembly both include windings for causing independentrotation of the first rotor assembly and the second rotor assembly,respectively. A printed circuit board is mounted to the housing overmoldand programmed to independently control the first and second rotorassemblies.

In a narrower aspect, a circuit board cover is attached to the housingovermold and covering the printed circuit board. Also in a narroweraspect, terminals are operably connected to the PCB and extending fromthe housing overmold for connection to motors control system outside thedevice.

Related methods are also contemplated to be within a scope of thepresent invention.

The unitary housing structural details as disclosed herein are alsocontemplated to be within a scope of the present invention.

An object of the present invention is to provide an integrated devicethat provides two (or more) independently controlled fluid flowfunctions, and provide on-board electrical control to vary the flow ratefor each fluid circuit.

An object of the present invention is to provide a flexible designallowing fluid connections to be integrally made (such as an inlet andan outlet for each of different fluid circuits).

An object of the present invention is to provide a housing integrallyformed to support the entire device for mounting to a selectedapplication (such as a vehicle), including incorporating brackets ormounting features without the need for secondary components.

In one aspect of the present invention, a device comprising a housing,at least two pumps, associated side-by-side shafts, and at least oneelectric motor operably connected to each pump and supported on anassociated one of the shafts for operation within the housing. Thehousing forms at least a portion of fluid passages to and from each pumpand also supports at least part of a motor control circuit for eachmotor.

In another aspect of the present invention, a pump device includes firstand second motors each including a stator and a rotor, associatedside-by-side shafts supporting the rotors, and a uni-body holding thestators of the first and second motors with the shafts in parallel andwith the rotors of the first and second motors rotatably supported onthe parallel shafts. The device further includes a pump on each rotorand a control circuit operably connected to the first and second motorsand supported by the uni-body.

In one aspect of the present invention, a device comprising a housing,at least two pumps, and at least one shaft. The device includes aninside electric motor and an outside electric motor operably connectedto different ones of the pumps and supported within the housing on theat least one shaft for operation within the housing, the housing formingat least a portion of fluid passages to and from each pump and at leastpart of a motor control circuit for each motor supported by the housing.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a chart showing potential applications having multiplefunctional subsystems requiring fluid flow, and shows an integratedmotor and pump device for satisfying at least two of the subsystems;

FIG. 2 is a chart similar to FIG. 1, but showing a device with three ormore pumps for satisfying multiple subsystems;

FIG. 3 is a side view of an over/under shared shaft motor and pumpdevice embodying the present invention, one motor being inside a secondmotor;

FIG. 4 is a side schematic view of the inline dual-motor pump devicenoted in FIG. 3;

FIGS. 5-6 are side and end views of the side by side dual-motor pumpdevice noted in FIG. 3;

FIG. 7 is a is a side schematic view of the inline dual-motor pumpdevice notice in FIG. 3;

FIGS. 8-10 are three different perspective views of a prototype of thein-line dual-motor pump device like that described and shown in FIG. 4;

FIG. 11 is a longitudinal cross section of the device of FIGS. 9-10,showing a flow of fluid through a first pump and showing cooling of theprinted circuit board (PCB) control;

FIG. 12 is a longitudinal cross section of the device of FIGS. 9-10,showing a flow of fluid through a second pump;

FIGS. 13-14 are end views of the device in FIGS. 9-10;

FIG. 15 is a perspective view of the device in FIGS. 9-10 with theover-molded polymeric material of the stator removed to show the statorwindings, end plates with motor control connector circuits and rotorposition sensors, and related components;

FIGS. 16-17 are perspective views of one motor's stator components inFIG. 15 with the over-molded polymeric material of the stator removed,FIG. 16 having the end plate removed and FIG. 17 having the end plateassembled;

FIG. 18 is a perspective view of the device of FIG. 20 but with the PCBboard removed to expose the PCB board;

FIGS. 19-20 are left and right perspective views of a side-by-side dualmotor, pump, and control device;

FIG. 21 is a longitudinal cross section of the device of FIGS. 19-20,showing a flow of fluid through the two pumps;

FIG. 22 is an end view of the device in FIG. 20;

FIG. 23 is a perspective view of the device of FIG. 20 but with the PCBcover removed to expose the PCB board;

FIG. 24 is a view similar to FIG. 21;

FIGS. 25-26 are left and right perspective views of an inside-outsidedual motor and pump device embodying the present invention, with theinside motor being physically substantially inside the outside motor andwith the pumps having inlets at opposing ends of the device and outletsextending in perpendicular directions;

FIG. 27 is a longitudinal cross section of the device of FIGS. 25-26,showing a flow of fluid through the two pumps and cooling of a printedcircuit board (PCB) controller;

FIG. 28 is an enlarged view similar to FIG. 27;

FIGS. 29-30 are end views of opposite ends of the device in FIGS. 25-26;

FIG. 31 is a view similar to FIG. 25 but taken from a bottom side andhaving the main upper volute (208) and PCB cover (209) removed to bettershow underlying components;

FIGS. 32-33 are top and perspective views of the stator assembly of FIG.28;

FIGS. 34-35 are perspective and top views of the lamination stack of thestator of FIGS. 32-33, the lamination stack providing a shared magneticflux carrier where a single stator laminate stack for both an ‘in-wound’and an ‘out-wound’ stator assembly; and

FIG. 36 is a longitudinal (side) cross sectional view similar to FIGS.27-28.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

A device embodying the present invention includes an integrated dualmotor and pump device, where the device includes at least two pumpsoperated independently by separate brushless DC (BLDC) motors andincorporating a unitary housing with optimized function, features, andcharacteristics for defined package space and minimized assembly costand time and components, while being optimized for operation. Theintegration of the device allows optimization of functions, features,and characteristics of both motors and pumps in the device, including acapability of designing for small package space and minimized assembly.For example, the present integrated unitary housing allows reduced costof manufacturing, reduced number of individual parts, less assemblytime, and less material handling and inventorying of parts andcomponents, since the integrated unitary housing can be overmolded in asingle overmold operation (or in a double overmold operation). Further,the unitary housing allows use of less total material (less total massof the device), and provides a more integrated and optimized design thattake greatest advantage of common use of components (e.g. electricalconnectors) while taking optimal advantage of polymeric materials in thehousing (such as by forming multiple fluid passageways with less totalpolymeric material). Also, the integrated design allows minimization ofpackage space. Still further, a single integrated circuit can beencapsulated or housed or carried by the housing, where the integratedcircuit is capable of managing and controlling each motor independently.

Thus, the illustrated two pumps can be controlled for independentoperation and variable output, providing significant operatingefficiencies to the product in which the dual motor and pump device(also called “tandem motor and pump device”) is attached. The presentdevice maintains design flexibility and a robustness of the overalldesign capabilities. Several different arrangements are shown herein,including an over/under motor with a single shaft version (FIG. 3), aparallel separate shaft version (FIGS. 4-5), and an in-line version(FIGS. 6-7). Each of these configurations support formation of sharedfluid ports shared electrical connector(s) and control circuitry andsensory components. Also, the present arrangements can be ganged (orcombined) for even greater efficiency of operation.

FIG. 1 shows that the present devices can be used in many differentapplications where multiple fluid systems are present. The differentapplications include, but are not limited to passenger vehicles(including automotive), aeronautical (including planes), nautical(including boats, yachts, ferries), mass transit vehicles (includingbuses), appliances (including but not limited to dishwashers, andclothes washers), industrial machines (part washers, and fluid-usingindustrial processes), and the like.

As illustrated in FIG. 1, the selected application 50 includes threesubsystems #1, #2, and #3. The present device 51 includes a dual motorand pump with integrated controller for moving fluid independently ineach of the three subsystems. Specifically, the device 51 includes afirst motor 54 and first pump 55 connected to a first sub-circuit 56(also called “power electronics”) of a control circuit in a controller52, and also includes a second motor 57 and second pump 58 connected toa second sub-circuit 59 of the control circuit of the controller 52. Thecontroller 52 is capable of receiving control information from amicrocontroller 53, where the microcontroller 53 is located either onthe device itself, or is separate from the device and operably connectedto the controller 52 by electrical connectors on a housing of the device51.

The housing of the device 51 includes an integrally unitary molding ofpolymeric material, such as a polymeric material having a high heattransfer capability. The housing is overmolded onto the motors andpumps, either in a single overmolding process or in a double overmoldingprocess, and includes forming components and features andcharacteristics for efficient operation. Note FIGS. 3, 4-5, and 6-7which show three different configurations of the housing. It iscontemplated that the overmolded housing will form structuralattachments (such as apertured flanges) for attaching the device to aspecific application 50, and form fluid passageways (including input andoutput connector ports) for the fluid communication to and from eachpump, and form structural support and accurate relational positioning ofcomponents (such as positions of the rotor and stator of the motor andpositions of bearings and other support relative to the pump), and formportions of each of the pumps, and provide support and protection forthe controller 52 (and related circuitry).

As shown in FIG. 1, the first motor/first pump are operably connected tothe subsystem #1. Also, the second motor/second pump are operablyconnected to the subsystems #2 and #3. (It is contemplated thatadditional subsystems could be added, as shown by dashed lines in FIG.1.) It is contemplated that the subsystems #2 and #3 can include asolenoid and valve or variable restrictor or other means to control arelationship of flow through the subsystems #2 and #3 if necessary ordesired.

The present innovative design allows flexibility in design of thehousing. For example, fluid channeling (fluid passageways) can beoptimized, to reduce 90 degree bends to provide gradual flow changes, orfiling and tailored channeling or contouring of channels (fluidpassageways). It also allows integration of sensors, including accuratepositioning without secondary attachment. For example, it iscontemplated that the sensors may include, but are not limited to,thermocouples and thermistors, flow meters, pressure transducers,accelerometers, and viscosity sensors. Also, the present innovationallows sensorless commutation, alternative termination techniques, andintegration of volute to any interface (such as a valve body, etc).Connectors and couples for electrical communication can be provided forthe entire mechatronic unit, including solenoids, valves, auxiliarymotors, all connected through a single connector. This allows an overallreduction in the number of components, and a reduction in assembly timeand time for connecting the device 50 once attached to a specificapplication 50. The present design allows for electromagnetic bondingand also adhesive assembly. Where the in-line version motor/pump is used(see FIGS. 6-7), a single shaft can be used for both pumps, with twodifferent stators being overmolded or assembled into a same assembly.Where an inwound/outwound version motor/pump is used (see FIG. 3), ashared stator or separate stators stacks with line-to-line-fit OD and IDsurfaces can be used.

The overmolded housing can integrally form a volute for an interface,including for example a volute shaped to operably receive (and coupleto) a customer valve body or auxiliary manifold. Multiple subsystemscontrols can be constructed using the present innovation, such as asingle control electronics module for controlling multiple mechatronicelements (valves, auxiliary pumps, solenoids, etc.). Also, the controlscan provide management of multiple subsystems requirements and initiateappropriate hydraulic response (such as for coolant, oil pressure,etc.). Also, the controls can reduce a total number of vehicleharnessing and connectors, reduce wiring, and simplify systems, thusgreatly reducing total cost, total number of components, and reducingmanual assembly time. Optimized sensors integrated into the controlsystem provide direct feedback response, such as pressure, flow,temperature, viscosity, acceleration, and other fluid data. Theovermolded housing allows fluid channeling optimization, includingcontouring and location of flow paths to reduce abrupt turns, optimizegradual flow path bending while minimizing overall length of the flowpath and minimizing material mass necessary to form the flow pathchanneling. An additional benefit is that the system cools electronicsand the motor(s) using proximity of pumped fluid as a heat transfermedium, thus removing heat from the motor and electronics, to thusincrease service life and improve overall operation.

FIGS. 3, 4-5, and 6-7 illustrate three different contemplated motor/pumpconfigurations.

Each of these designs are IP69 compliant, with improved sealability offluids (i.e., low likelihood of leakage) over known fluid pump systems.They each are capable of incorporating different style bearings and/orbushings. They offer reduced package size, reduced total mass, reducednoise during operation as well as reduction of total components. Theyeach offer excellent thermal management, particularly when athermally-conductive polymer is used, such as a polymer having a thermalconductivity of more than 0.02 w/m·K at 25 degrees C. Overmolding of thehousing allows two or more stators to be integrated into and securelypositioned in a single overmold step. Sensors can also be integrated inthe overmold step, such as from lead frame to media stream directsensors. A wide range of termination techniques can be used, includingcompliant pin, IDC, fusing, and welding. Sensorless commutation issupported by this design innovation, as well as electromagnetic bondingand/or adhesive assembly.

FIG. 4 illustrates an over/under motor and pump arrangement. A singlestator is fixed by the overmolded housing, and a first rotor/motor isformed inside, and a second rotor/motor is formed outside. A singleshaft is provided, with a first pump at a first end of the device (rightside of the drawing), and a second pump at an opposite left end of thedevice (left side of the drawing). Fluid flow is shown by dashed line.The motors and pumps are supported for independent rotation on the shaftand for independent operation.

FIGS. 5-6 illustrates a side-by-side motor and pump arrangement. In thisarrangement, the housing integrally forms adjacent motors (with axes ofthe motors extending in parallel directions), and further supports allbearings and structural support for operation of the two side-by-sidemotors. The housing also defines fluid passageways and other structurerequired for supporting operation of the pumps. As illustrated, thepumps are located at opposite ends of the housing, and communicate fluidalong a center plane of the housing. It is noted that a balance and“counterflow” design of this version can provide benefits of noise andvibration reduction. Also, this design positions significant mass atcritical areas, such as around bearings at opposite ends of each motorshaft. At the same time, the present arrangement minimizes mass innon-critical areas, such as the minimal slug of material along a centerof the housing in between the two different fluid passageways, whichslug forms both a portion of the upper passageway and also a portion ofthe lower passageway in a manner minimizing total material mass.

FIG. 7 illustrates an in-line motor and pump arrangement. In thisarrangement, the overmolded housing forms the two motors on oppositeends of a shared shaft. In this arrangement, each motor and associatedpump ride on opposite ends of the common shaft. However, the motors andpumps are operably independent of the shaft, such that they provideindependent pumping capability, and capacities.

The present devices provide two (or more) independently controlled fluidflow functions, and provide on-board electrical controls to vary theflow rate for each fluid circuit. They also provide a way to formflexibly-designed fluid connections (such as an inlet and an outletalong with leak-free connecting structure for each of two differentfluid circuit). The housing is integrally formed to support the entiredevice for mounting to a selected application (such as a vehicle),including incorporating brackets or mounting features without the needfor secondary components. The device is complete and highly fluid-leakresistant when properly connected, due to its integrated design.

The present innovative designs provide a dual pump using two brushlessDC (BLDC) motors driving pumps independently, including hydraulicintegration. This is accomplished via several arrangements including aninside/outside motor version (FIG. 4), parallel separate shaft version(FIGS. 5-6), and an in-line version (FIG. 7). Each of theseconfigurations include a housing supporting formation of fluid ports,shared electrical connector(s) and control circuitry and sensorycomponents. Also, the present arrangements can be ganged (or combined)for even greater efficiency of operation.

It is contemplated that a scope of the present invention includes, forexample, a housing; a microcontroller; two pumps, two independentlycontrolled motors, and includes one or more of:

-   -   wherein the housings overmolded into a single unitary component        and encapsulates at least part of the two motor assemblies;        and/or    -   wherein the housing is molded using a thermally conductive        polymer; and/or    -   wherein the housing contains fluid channels to remove heat from        the motors and electronics; and/or    -   wherein the housing contains fluid channels porting the pumped        media from at least one integrated pump to remove heat from the        motors and electronics; and/or    -   wherein the housing contains electrical leads that interconnect        to each motor; and/or    -   wherein the housing contains electrical interconnects to at        least one auxiliary devices in addition to the motor controllers        (e.g., valve body, clutch, switches, or etc.); and/or    -   wherein the housing contains mounting features to integrate        fluid output ports in a communicative fluid arrangement with a        subsystem; and/or    -   wherein the microcontroller has at least one master        microcontroller and one slave microcontroller independently        controlling at least one motor per controller; and/or    -   wherein the microcontroller has at least two motor driver        circuits independently controlling at least two motors; and/or    -   wherein the housing includes fluid channeling to enhance laminar        flow of media, reduce turbulence in pumped fluid; and/or    -   wherein the housing includes sensor position cavities, retaining        features and electrical interconnects to the sensor; and/or    -   wherein the sensor monitors and provides feedback to the        microcontroller for at least one motor or pump performance        characteristic; and/or    -   wherein the motor resonances are matched to offset resonance        vibration from the motor and/or environmental influences; and/or    -   wherein the motor acoustic frequencies are matched to dampen        acoustical noise from the other motors and/or environmental        influences; and/or    -   wherein the motors are controlled through multiple        microprocessors and drive circuits onboard a single printed        circuit board assembly mounted within the housing, potentially        within a vehicle or subsystem; and/or    -   wherein the motors are controlled through multiple        microprocessors and drive circuits onboard a single printed        circuit board assembly mounted within a vehicle or subsystem;        and/or    -   wherein the motors are controlled through a master        microprocessor receiving commands from at least one subsystem,        and at least one slave microprocessor configured to receive        commands from the master microprocessor, the circuits onboard a        single printed circuit board assembly mounted within the        housing; and/or    -   wherein the motors are controlled through an integrated motor        controller processor with discrete drive circuits onboard a        single printed circuit board assembly mounted within the        housing; and/or    -   wherein polymer fillers and flow direction of the polymer during        injection molding are designed and oriented such that thermal        transfer is optimized to add or remove heat from targeted areas        of the housing along predetermined heat flow paths (such as heat        conduction along oriented glass fibers for optimal performance).

Modification

The present device 70 (FIGS. 9-10) is a further-improved device similarto the device shown in FIGS. 6-7. The device 70 is a shared-shaft dualmotor, double-pump, and single-control arrangement including a singleshaft 71 (FIG. 12) with first and second motors 72 and 73 adjacentlypositioned on each end. The motor 72 includes a rotor 74, a stator 75with windings 76, and an end-mounted circuit/sensor/connector board 77(also called “end plate”) for sensing a position and controllingoperation of the rotor 74 for motor control. The motor 73 includes arotor 80, stator 81 with windings 82, and an end-mountedcircuit/sensor/connector board 83 for sensing a position and controllingoperation of the rotor 80. A uni-body 85 (also called a “housingovermold”) of polymeric material is over-molded onto and encapsulates amajority of the stators 75 and 81 and holds them in an aligned positionon the shaft 71. Notably, the rotor-interfacing surfaces of the stators75 and 81 are not covered with polymeric material, thus providingoptimal close interfaced operation with an outer surface of the rotors74 and 80. Electrical contact tabs 86 and 87 extend through the uni-body85 (also called a “housing overmold” herein) for connection to a printedcircuit board (PCB) controller 88 (FIGS. 12, 18), which provideson-board control over the motors 72, 73. A cover 89 covers the PCBcontroller 88.

Pumps 90 and 91 are formed at outboard ends of the motors 72, 73,respectively. The first pump 90 includes an impeller 92 on an end of therotor 74 for rotation on the shaft 71, and includes a pump head 93 (alsocalled a “volute” or “end cap” herein) covering an outer surface of theimpeller 92. The illustrated impeller 92 can be a separate part or canbe formed from over-molded polymeric material that also encapsulatesmagnets and other components of the rotor 74. Notably, the presentinnovation is believed to encompass several ways for forming and/orattaching the impeller. For example, the impeller can be a two-piece ormulti-piece assembly or a unitary molding by itself, or a unitarymolding that also forms part of the rotor itself. The pump head 93defines an inlet 94 with centered axial liquid passageway to theimpeller 92 (including a lip 95 for secure connection to a hose orconduit), a pump chamber 96 with an end of the uni-body 85, passageways97 (see also FIG. 11) extending axially along the uni-body 85 includingportions near the PCB controller 88, and an outlet 98 (FIG. 9) withretainer lip 99, the outlet 98 extending from the uni-body 85 at an endopposite the inlet 94. The passageways 97 are configured to cool the PCBcontroller 88 simultaneous with pumping the liquid. For example, theliquid being pumped by pump 90 might be radiator antifreeze for coolinga combustion engine of a passenger vehicle.

The second pump 91 includes an impeller 102 attached to an outboard endof the rotor 80 for rotation on the shaft 71, and includes a pump head103 (also called a “volute” or “end cap” herein) covering an outersurface of the impeller 102. The illustrated impeller 102 is formed fromover-molded polymeric material that also encapsulates an inner portionof the rotor 80. As noted above, the present innovation is believed toencompass other ways for forming and/or attaching the impeller. Forexample, the impeller can be a two-piece assembly or a unitary moldingby itself, or a unitary molding that also forms part of the rotoritself. The pump head 103 defines an inlet 104 with centered axialliquid passageway to the impeller 102 (including a lip 105 for secureconnection to a hose or conduit), a pump chamber 106 with an end of theuni-body 85, a passageways 107 extending tangentially from the uni-body85 and rotor 80, and an outlet 108 (FIG. 9) with retainer lip 109, theoutlet 108 extending from the uni-body 85 at a same end as the outlet98. For example, the liquid being pumped by pump 91 might betransmission fluid for cooling a transmission for a combustion engine ofa passenger vehicle.

FIG. 11 is a longitudinal cross section of the device of FIGS. 9-10,showing a flow of fluid through the first pump 90 and showing cooling(see red parallel lines extending from the PCB controller 88 toward thepassageway 97) of the printed circuit board (PCB) controller 88. It isnoted that the illustrated rotors 74 and 80 ride on a thin film ofliquid covering the shaft 71. It is contemplated that other stylebearing arrangements or bearing systems could be incorporated ifdesired.

FIG. 12 is a longitudinal cross section of the device of FIGS. 9-10along an axial centerline of the assembly, including a showing of a flowof fluid through the second pump 91.

FIGS. 13-14 are end views of the device in FIGS. 9-10.

FIG. 15 is a perspective view of the device in FIGS. 9-10 with theuni-body 85 of over-molded polymeric material of the stators removed toshow the stator windings, FIG. 15 also showing end plates with motorcontrol connector circuits and rotor position sensors, and relatedcomponents.

FIGS. 16-17 are perspective views of one motor's stator components inFIG. 15 with the over-molded polymeric material of the stator removed,FIG. 16 having the end plate removed and FIG. 17 having the end plateassembled.

FIG. 18 is a perspective view of the device of FIG. 10 but with the PCBboard removed to expose an outboard side of the PCB board.

Second Modification

The present device 300 (FIGS. 19-20) is a device similar to the deviceshown in FIGS. 5-6, but further improved. The device 300 is aside-by-side dual motor, double-pump, and single-control arrangementincluding side-by-side shafts (FIG. 22) with first and second motorsadjacently positioned in side-by-side relation. As shown in FIG. 24, thecomponents include an auxiliary upper volute 301 (also called “pumpcasing cap” herein), an auxiliary rotor assembly 302, an auxiliarystator assembly 303, an auxiliary pump shaft 303 with pump impellers304A, a main pump shaft 105 with pump impellers 305A, a main statorassembly 306, a main rotor assembly 307, a main upper volute 308 (alsocalled “pump casing cap” herein), a printed circuit board (PCB) cover309, a printed circuit board 310 providing controls for the two motors,a plurality of motor terminals 311 (six being illustrated), and ahousing overmold 312. It is contemplated that the adjacent motors andpumps can be varied substantially and still be within a scope of thepresent invention. Accordingly, although the illustrated components aredescribed using the words “auxiliary” and “main”, this is not intendedto be unnecessarily limiting.

The first main motor includes components 305-307 and the main pumpincludes components 305A, 308 and some pump casing portions and pumpfluid passages being created by the housing 312. Also, the second(auxiliary) motor includes components 302-304, and the second(auxiliary) pump includes components 304A, 301 and some pump casingportions and pump fluid passages being created by the housing 312. Theperformance of the first and second motors and pumps can be designed forparticular applications. For example, a prototype like that shown inFIG. 24 has been constructed for use on a passenger vehicle, where theauxiliary pump creates a flow of 0-20 LPM, a pressure of about 60 kPa,handling fluid temperatures of −40 to 120 degrees C., with minimumvoltage of 9 volts, shaft speed of 800-4500 RPM, and shaft torque of0.065-0.12 Nm. Also in the example, the main pump creates a flow of 0-80LPM, a pressure of about 60 kPa, handling fluid temperatures of −40 to120 degrees C., with minimum voltage of 9 volts, shaft speed of 500-5000RPM, and shaft torque of 0.25-0.50 Nm.

The PCB 310 is operably connected to sensors on the motors and pumps forsensing a position and controlling operation of their respective rotorsfor motor control in relation to pump conditions and desired pumpoperation. The uni-body 312 (also called a “housing” or “housingovermold”) is a polymeric material over-molded onto and encapsulating amajority of the stators 303 and 306. The housing 312 holds the stators303 and 306 in a parallel adjacent position on the respective shafts 304and 305. Notably, the rotor-interfacing surfaces of the stators 303 and306 are not completely covered with polymeric material, thus providingoptimal close interfaced operation with an outer surface of the rotors302 and 307. Electrical contact tabs (terminals) 311 extend from theuni-body 312 for connection to a printed circuit board (PCB 310), whichacts as a controller for the motors and pumps. The PCB 310 provides anon-board control over the two motors, and can be made responsive to amaster vehicle electrical system circuit and control device. A covercovers the PCB 310 to protect the circuitry and keep out moisture.

The illustrated side-by-side pumps are formed at outboard ends of thetwo motors on the same side of the device 300 and their input and outputpassageways extend in parallel directions, though it is contemplatedthat the pumps could be on opposite sides of the housing 312 and/ortheir outlets could be in different directions if a particularapplication required that. It is contemplated that the impellers of eachpump can be a separate part or can be formed from over-molded polymericmaterial that also encapsulates magnets and other components of therotors. Notably, the present innovation is believed to encompass severalways for forming and/or attaching the impeller. For example, theimpeller can be a two-piece or multi-piece assembly or a unitary moldingby itself, or a unitary molding that also forms part of the rotoritself.

The illustrated first pump includes an inlet 320, outlet 321, and pumpcavity 322 formed by the upper volute 308 and housing 312, with the pumpimpeller 305A within the cavity 322. The illustrated second pumpincludes an inlet 323, outlet 324, and pump cavity 325 formed by theauxiliary volute 301 and housing 312, with the pump impeller 304A withinthe cavity 325. The inlet and outlets 320, 321, 323, 324 include a lipfor secure connection to a hose or conduit to convey liquid, such asantifreeze, transmission fluid, power steering fluid, turbochargercoolant or other coolant.

FIG. 21 is a longitudinal cross section of the device of FIGS. 19-20,showing a flow of fluid through the two pumps, and FIG. 22 is an endview of the device in FIG. 20. FIG. 23 is a perspective view of thedevice of FIG. 20 but with the PCB board removed to expose the PCBboard, and FIG. 24 is a view similar to FIG. 21.

Third Modification

Present device 200 (FIGS. 25-26) is a device similar to the device shownin FIGS. 5-6, but further improved. The device 200 is an inside-outsidedual motor (also called “over under dual motor”), double-pump, andsingle-control arrangement including a first inside motor positionedsubstantially inside a second outside motor. As shown in FIGS. 27-28,and 36, the components include an auxiliary upper volute 201 (alsocalled “pump casing cap” herein), an auxiliary rotor assembly 202 (alsocalled an “auxiliary rotor”), an auxiliary stator assembly 203 (alsocalled auxiliary “stator” herein), a shaft 204 with pump impellers 204Aand 205A at each end, a termination substrate 205, copper windings 206wrapped onto protrusions of the stator lamination stack 206A forming amain statorassy (also called a “main stator” herein), a main rotorassembly 207 (also called a “main rotor”), a main upper volute 208 (alsocalled “pump casing cap” herein), a printed circuit board (PCB) cover209, a printed circuit board (PCB) 210 providing controls for the twomotors, a plurality of motor terminals 211 (six being illustrated), anda housing overmold 212. It is contemplated that the adjacent motors andpumps can be varied substantially and still be within a scope of thepresent invention. Accordingly, although the illustrated components aredescribed using the words “auxiliary” and “main”, this is not intendedto be unnecessarily limiting.

The performance of the first and second motors and pumps can be designedfor particular applications. For example, a prototype like that shown inFIG. 36 has been constructed for use on a passenger vehicle, where theauxiliary pump creates a flow of 0-20 LPM, a pressure of about 60 kPa,handling fluid temperatures of −40 to 120 degrees C., with minimumvoltage of 9 volts, shaft speed of 800-4500 RPM, and a shaft torque of0.065-0.12 Nm. Also in the example, the main pump creates a flow of 0-80LPM, a pressure of about 60 kPa, handling fluid temperatures of −40 to120 degrees C., with minimum voltage of 9 volts, shaft speed of 500-5000RPM, and shaft torque of 0.25-0.50 Nm.

The PCB 210 is operably connected to sensors on the motors and pumps forsensing a position and controlling operation of their respective rotorsfor motor control in relation to pump conditions and desired pumpoperation. The uni-body 212 (also called a “housing” or “housingovermold”) is a polymeric material over-molded onto and encapsulating amajority of the stators 203 and 206/206A. The housing 212 holds thestators 203 and windings 206 in position around the shaft 204. Notably,the rotor-interfacing surfaces of the stator 203 are not completelycovered with polymeric material, thus providing optimal close interfacedoperation with the effective surface of the rotors 202 and 207.Electrical contact tabs (terminals) 211 extend from the uni-body 212 forconnection to a printed circuit board (PCB 210), which acts as acontroller for the motors and pumps. The PCB 210 provides an on-boardcontrol over the two motors and can be made responsive to a mastervehicle electrical system circuit and control device. A cover covers thePCB 210 to protect the circuitry and keep out moisture.

The illustrated pump impellers are located at opposite ends of thedevice 200, with the their respective inlets 220 and 223 being alignedat opposite sides of the housing 212, and with the respective outlets221 and 224 facing laterally at 90 degree orientations relative to eachother. Notably, it is contemplated that the outlets could extend indifferent directions if a particular application required that. It iscontemplated that the impellers of each pump can be a separate part orcan be formed from over-molded polymeric material that also encapsulatesmagnets and other components of the rotors. Notably, the presentinnovation is believed to encompass several ways for forming and/orattaching the impeller. For example, the impeller can be a two-piece ormulti-piece assembly or a unitary molding by itself or a unitary moldingthat also forms part of the rotor itself.

The illustrated first pump includes an inlet 220, outlet 221, and pumpcavity 222 formed by the upper volute 208 and housing 212, with the pumpimpeller 205A within the cavity 222. The illustrated second pumpincludes an inlet 223, outlet 224, and pump cavity 225 formed by theauxiliary volute 201 and housing 212, with the pump impeller 204A withinthe cavity 225. The inlet and outlets 220, 221, 223, 224 each include alip for secure connection to a hose or conduit to convey liquid, such asantifreeze, transmission fluid, power steering fluid, turbochargercoolant or other coolant.

FIG. 31 is a view similar to FIG. 25, but taken from a bottom side andhaving the main upper volute (208) and PCB cover (209) removed to bettershow underlying components. FIGS. 32-33 are top and perspective views ofthe stator assembly of FIG. 28, and FIGS. 34-35 are perspective and topviews of the lamination stack of the stator of FIGS. 32-33. Also, FIG.36 is a longitudinal (side) cross sectional view similar to FIGS. 27-28.Notably, as illustrated, fluid pumped through the device 200 by the twopumps both cools the device 200 (including cooling of the PCB 210) andalso acts as a lubricating coating on the rotor assemblies.

In regard to the lamination stack in FIGS. 32-33, an object of thepresent invention is to provide a shared magnetic flux carrier. Forexample, as illustrated, it would include a single stator laminate stackwith in-wound and out-wound stator teeth for both an ‘in-wound’ and an‘out-wound’ stator assembly. The illustrated lamination stack includes acommon back iron that channels the flux between the out-wound statorteeth and the in-wound stator teeth along substantially discrete fluxpaths on the same back iron. It is possible to press two individualstator stacks together either with or without a separator sleeve.However, it is contemplated that it is not only possible butadvantageous to use a single lamination for two stator assembliesdriving two separate rotors and pumps for two discrete outputparameters.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A combination dual pump and dual motor device comprising: a housing overmold; first and second shafts that are parallel and non-aligned and each having an overmold-supported portion supported by the housing overmold; a first volute attached to a first outer end of the first shaft and with the housing overmold defining at least portions of a first pump cavity at the first outer end and a first inlet to the first pump cavity and a first passageway extending from the first pump cavity to a first outlet; a first rotor assembly operably engaging the first shaft and having a first pump impeller in the first pump cavity; a second volute attached to a second outer end of the second shaft and with the housing overmold defining at least portions of a second pump cavity at the second outer end and a second inlet to the second pump cavity and a second fluid passageway extending from the second pump cavity to a second outlet; a second rotor assembly operably engaging the second shaft and having a second pump impeller in the second pump cavity; a first stator adjacent the first rotor assembly and a second stator adjacent the second rotor assembly, both the first and second stators including windings for causing independent rotation of the first rotor assembly and the second rotor assembly, respectively; a printed circuit board mounted to the housing overmold and programmed to independently control the first and second rotor assemblies.
 2. The combination dual pump and dual motor device in claim 1, including a circuit board cover attached to the housing overmold and covering the printed circuit board.
 3. The combination dual pump and dual motor device in claim 1, including terminals operably connected to the printed circuit board and extending from the housing overmold for connection to motors control system outside the device.
 4. The combination device in claim 1, wherein the second inlet and second outlet extend in directions that are 90 degrees from each other.
 5. The combination device in claim 1, wherein the first and second inlets extend parallel to each other and extend from a same end of the device.
 6. The combination device in claim 1, wherein the first and second inlets define parallel directions, and the first and second outlet define parallel directions.
 7. The combination device in claim 1, wherein the first and second inlets extend co-linearly with the first and second shafts, respectively.
 8. The combination device in claim 1, wherein the housing overmold engages and supports the winding of both the first and second stators.
 9. The combination device in claim 1, wherein the first and second pump impellers are different sizes.
 10. The combination device in claim 1, wherein first and second inlets are different sizes.
 11. The combination dual pump and dual motor device of claim 1, wherein the housing overmold includes structure directly supporting the printed circuit board over non-pump ends of the first and second shafts opposite the first and second volutes.
 12. A combination dual pump and dual motor device comprising: a housing overmold; first and second shafts that are parallel and non-aligned and each having an overmold-supported portion supported by the housing overmold; a first volute attached to a first outer end of the first shaft and with the housing overmold defining a first pump cavity at the first outer end and a first inlet to the first pump cavity and a first passageway extending from the first pump cavity to a first outlet; a first rotor assembly operably engaging the first shaft and having a first pump impeller in the first pump cavity; a second volute attached to a second outer end of the second shaft and with the housing overmold defining a second pump cavity at the second outer end and a second inlet to the second pump cavity and a second fluid passageway extending from the second pump cavity to a second outlet; a second rotor assembly operably engaging the second shaft and having a second pump impeller in the second pump cavity; a first stator adjacent the first rotor assembly and a second stator adjacent the second rotor assembly, both the first and second stators including windings for causing independent rotation of the first rotor assembly and the second rotor assembly, respectively; and a printed circuit board mounted to the housing overmold and programmed to independently control the first and second rotor assemblies; the housing overmold including structure directly supporting the printed circuit board over non-pump ends of the first and second shafts opposite the first and second volutes. 